Apparatus for textile dyeing

ABSTRACT

This application is directed to a device and method for applying dye to fabric. The device includes an oscillatory wiper blade which channels dye into streams; the falling streams are divided by a moving wire member supported on a circulating band. A portion of the dye may then be distributed onto the teeth of an adjustable comb-like device from which the dye finally drips upon the fabric to form an irregular pattern. The remainder of the dye falls directly onto the fabric, after being subdivided by the circulating band.

United States Patent J Appenzeller et al. May 8, 1 973 [54] APPARATUS FOR TEXTILE DYEING [56] References Cited [75] inventors: Valentin Appenzeller, Kem- UNITED STATES PATENTS gg'gflfi'ggfgfljgggfig'flfif 3,570,275 3/1971 Weber et al ..68/205 R 3,614,880 l0/l971 Bayne et al. ..68/205 R Assigne Schroers & Co., Krefeld, Germany P'imary Examinep-William I. Price r Attorney-Kenyon & Kenyon Reilly Carr & Chapin [22] Filed: March 1, 1971 21 Appl. No.: 119,540 [571 ABSTRACT This application is directed to a device and method for [30] Foreign Application him-y applying dye to fabric. The device includes an oscillatory wiper blade which channels dye into streams; the May 1970 Germany 20 343-9 falling streams are divided by a moving wire member supported on a circulating band. A portion of the dye :Lfl. may then be distributed onto the teeth of an adjusta ll ble ik device from which h dye finally drips [58] Fleld 0 Search 205 R; I p the fabric to form an irregular pattern. The remainder of the dye falls directly onto the fabric, after being subdivided by the circulating band.

9 Claims, 1 Drawing Figure APPARATUS FOR TEXTILE DYEING BACKGROUND It is sometimes desirableto finish a single color carpet in such a way that although the single color remains the dominant base tone, a liveliness or an optically improved effect is imparted thereto. This may be accomplished by applying the single color in a manner to achieve differing tones. The color differences are evident despite the optically unified appearance of the total surface. However, thecolor difference should not appear as a'regulated pattern or design of a particular geometry. Further, the pattern should not appear in regularly recurring portions, rather it should form a certain unified irregularity or randomness which is esthetically pleasing to the eye. Such a type of carpet dyeing process has been commonly designated as Space Dyeing. This type of patterning has further achieved significance in other fabrics, as for example is substantially nonrepetitive over a distance of the textile sufficient to make the pattern appear random to the human eye. To further prevent any linear or repetitive type of pattern, a grid means is positioned between the dye dispensing means and the textile. The grid means may also be oscillated to further randomize the appearance of the dye pattern.

An object of the present invention is to provide novel means for dyeing textiles which may, in part, utilize devices set forth in said pending patent application, the

decorative fabric materials. Accordingly, although the a remaining discussion will be directed to carpets, it is noted that it is equally applicable to any textile materia1.

Various proposals have been made recently to achieve the above-mentioned dyeing and patterning process. One of these proposals has been to apply different dyes and colors to the thread spools and to tuft the various dyed threads. Alternatively, it has been proposed to print the threads with different colors prior to tufting. Another proposal includes making a stocking of undyed thread, priming the stocking, printing it with color, steaming it, raveling it again and then tufting the thus colored thread. As may be readily seen, these processes are inherently expensive. For example, in the latter process such a great quantity of prepared thread must be maintained in storage that it becomes impossible to maintain a sufficient variety to satisfy the number of differing requirements. Another of the processes contained in the prior art includes the spraying of a single color onto the carpet by means of a pressurized jet or discharge nozzle. Sometimes, a mixture of gas is included with the liquid causing the dispersion of minute droplets conically toward the material under treatment. Such a process is limited in that it may only be utilized in a single color dyeing operation. In the proposed operation of such a process, pressurized discharge nozzles have been disposed over the entire width of the carpet under treatment. with adjacently spaced rows of nozzles being offset from one another. Circuit schemes mustbe provided to facilitate the switching on and off of individual or multitudes of rows of nozzles to achieve a random and nonrepetitive type of pattern. This process has achieved a limited degree of success in that it is possible to achieve the desired random pattern. However, because of the individually controlled mechanisms of each nozzle the system has proven costly and subject to failures by means of clogging and coagulation in the nozzles.

An improved means for the dyeing of fabrics is set forth in pending patent application Ser. No. 831,297, filed June 9, 1969, by Takriti, Quoos, Leifeld and Appenzeller. This application discloses a method and apparatus for applying individual droplets of a dye material to a textile, carpet, or the like which is being passed through the dyeing machine. The droplets are dispensed from a doctor blade through channels apdescription of which is incorporated herein by reference thereto.

A primary object of the invention is to provide for a simplified method and apparatus for imparting a dye pattern onto a textile type material which presents a substantially random appearance as desired.

These and other objects, advantages and features of this invention will appear from the following detailed description of the invention.

THE INVENTION This invention is directed to a mechanism for the continuous dyeing of textile webs, such as pile carpeting, preferably those with a solid base color. The same or different colors are applied to the carpet without a prominent regularity of design. The dye is applied to the topside or pile side of a continuously moving length of the fabric by liquid dye streams which are formed on a doctor blade having channels or grooves thereon. The doctor blade, which is subjected to an oscillatory motion, provides a veil of streams of dye positioned along a line perpendicular to the direction of the movement of the fabric. The falling streams of dye are interrupted by wire members which follow a revolving path through the dye streams. A portion of the interrupted dye streams falls directly upon the carpet. and the remainder falls upon the teeth of a comb-like device from which the dye drips onto the textile.

This invention will be further defined by reference to the accompanying FIGURE. The drawing illustrates schematically an example of the invention in a perspective rendering.

The pile material textile l which is to be dyed with a pattern, has been previously pad-dyed a solid color and the dye has been pressed out. The arrow 2 denotes the forward direction of the textile.

The dye discharger, which has been marked 20 in its entirety is being underrun by the textile l with its pile turned toward the direction of the oncoming dye. A rotating roller 21 dips into a trough 22 which is filled with liquid dye. The direction of :rotationof the roller 21 is indicated by an arrow 23. The drive mechanism for the roller is not illustrated. Conventional rotating drive means may be provided, for example, the axis of the roller may be connected through a V-belt to an electric motor. The drive speed of the electric motor can be adjustable to control the amount of liquid taken up by the roller. The top edge of a doctor blade 27 is in contiguous engagement with roller 21 and removes the dye film from the surface of the roller. The doctor is inclined downwardly as illustrated. The doctor is preferably not at a steep angle with respect to the horizontal plane so that the film of dye does not flow too rapidly from the doctor. The dye liquid flows across the doctor and is separated into individual streams upon contact with the molded members 19. The molded members 19 are of triangular shape and protrude from the face of the doctor. These members terminate at the lower edge of the doctor and form channels 31 which are open at the top. The doctor is adapted to be moved in an oscillatory motion, as indicated by double arrow 80. The device for moving the doctor is illustrated by drive shaft 24 and drive means 25. The details of such device may be of conventional construction or may be the same as illustrated in copending patent application Ser. No. 831,297.

The dye liquid streams 81 during their descent tend toward forming drops. This separating process into drops is further induced and controlled by the slowly revolving band or ribbon member 82 with its wire webs 83, which cut the liquid dye streams. The direction of rotation of the band member is marked 84. The band member is arranged in a plane perpendicular to the dye liquid streams or in a plane parallel to the fabric length. The rollers 85 carrying the band member are driven by conventional means such as an electric motor. The distance of the webs 83 from one another is a fractional integer of the distance between the liquid dye streams from one another. The webs, in the illustrated example, are parallel to the directional axis of the movement of the textile.

Underneath the band member is a comb 86 with teeth 87. The teeth are positioned in the path of the liquid dye between the webs of the band member and the textile. The wire strength or thickness of the comb teeth may be the same or may be different from the wire strength of the webs on the band member. The ends 89 of the comb teeth are bent and rounded in an upward motion. The teeth 87 form accumulation areas for the dye liquid and the liquid precipitates in enlarged drops after efficient collection thereon. The comb may be moved into or out of the path of the liquid dye. The position of the angle of the teeth is adjustable with respect to he plane of said textile, by means of rotatable drive shaft 90 and drive means 91.

The oscillatory motion of the doctor blade is adjusted so that the falling streams form a veil of dye which effectively covers the entire width of the fabric therebelow. The mechanism of this invention leads to the interruption of the dye liquid streams into drops in such a manner that a regularity in the formation of the drops is achieved without interfering with their evenness. This is accomplished as described above by the band member. In accordance with this invention a strainer-like band member 81 has webs 83, preferably made from wire and having a circular transverse section. The band member circulates slowly and with a regular speed in an endless loop, cutting across the path of the dye liquid. The band member preferably revolves with a velocity of approximately 0.5 m/min. The web members substantially determine the resulting formation of the drops which fall from a height of 30 to 60 cm, by splitting the dye stream. A regularity of the formation of drops is achieved due to the low velocity of the webs which do not force the dye streams apart or cause splashing. The webs on the band are arranged generally parallel to the length of material or perpendicularly in reference to the liquid dye streams so that they have a dividing effect and form no, or almost no accumulations.

The distance between the strainer webs preferably forms an integral partial size of the distance between the liquid dye streams. This has the advantage that the webs always cut the liquid dye stream at the same time. Therefore, for instance, if the stream separation distance is 22 mm the distance between the webs is ll mm. Stated otherwise the ratio of the distance between webs to the distance between the channels is one to an integer. Alternatively if said distances between the webs is not a fractionalintegral of the stream separation, the random nature of the dye pattern may be altered.

The webs, which are arranged in a plane perpendicular to the dye streams form a plane parallel to that of the fabric. In the example illustrated the ribbon member circulates in an endless loop underneath the doctor. However, an arrangement is also possible, whereby only the lower strand of the ribbon member cuts through the liquid streams and the upper strand is positioned above the discharge point of the dye streams.

Below the band member is a comb with its teeth reaching into the dripping path of the dye liquid. The teeth form accumulation places for thedrops which fall thereupon and the drops only precipitate onto the fabric after having reached a certain size. By this technique the resulting design on the fabric is affected so that variations of a predetermined design are possible with this comb. The teeth of the comb are aligned in the same direction as the webs on the band member. The number of teeth is a multiple of the number of falling streams. The device illustrated can be operated with or without said comb.

It is also preferable that the comb teeth be movable at different angles to the fabric, so that the teeth are more or less set at an incline to the fabric, or are arranged in a parallel position to the fabric length. In this manner the enlargement of the drops may be controlled, which results in further influencing the design possibilities.

The pulsating flow of dye onto the teeth, due to the interrupting effect of the circulating band, leads to a useful flow pattern for that portion of the dye. The remainder of the dye, which does not flow onto the teeth, falls directly onto the carpet in a suitable drop pattern.

' The wire size of the comb teeth may be different from the wire size of the webs. Identical sizes are also possible. It is advantageous to bend the ends of the discharging teeth so that they are rounded off upwardly, which will facilitate a vertical precipitation onto the fabric chute.

This invention has been described in terms of specific embodiments set forth in detail. Alternative embodiments will be apparent to those skilled in the art in view of this disclosure, and accordingly such modifications are to be contemplated within the spirit of the invention as disclosed and claimed herein.

We claim:

1. In a device for the continuous dyeing of a moving textile in which liquid dye streams discharge onto the textile,

the improvement comprising means to divide said streams which includes a bandmember adapted to support webs afiixed thereto which are approximately parallel to the direction of movement of said textile, said band member adapted to circulate in an endless loop perpendicular to the direction of movement of said textile, and wherein said webs are positioned to pass through said dye streams.

2. The device of claim 1 comprising a doctor blade with a series of channels thereon, which lead to the formation of said liquid dye streams and means to impart an oscillatory motion to said doctor blade 3. The device of claim 2 wherein the distance between said webs is a fractional integer of the distance between said channels.

4. The device of claim 1 wherein the plane of said webs is substantially parallel to the plane of said textile positioned below said webs.

5. The mechanism of claim 1 wherein a comb-like device having teeth is positioned between said web and said textile in the discharge path of said dye.

6. The device of claim 5 wherein means is provided to adjust the angle of said teeth with respect to the plane of said textile therebelow.

7. The device of claim 5 wherein the teeth of said comb are rounded in an upward turn.

8. The device of claim 1 wherein said band member is supported and driven by a pair of rotating rollers positioned on opposite sides of said textile.

9. The device of claim 1 wherein said band member comprises two loop members positioned on opposite sides of a plane through said dye streams and said web members are supported at each end thereof by one of said loop members. 

1. In a device for the continuous dyeing of a moving textile in which liquid dye streams discharge onto the textile, the improvement comprising means to divide said streams which includes a band member adapted to support webs affixed thereto which are approximately parallel to the direction of movement of said textile, said band member adapted to circulate in an endless loop perpendicular to the direction of movement of said textile, and wherein said webs are positioned to pass through said dye streams.
 2. The device of claim 1 comprising a doctor blade with a series of channels thereon, which lead to the formation of said liquid dye streams and means to impart an oscillatory motion to said doctor blade.
 3. The device of claim 2 wherein the distance between said webs is a fractional integer of the distance between said channels.
 4. The device of claim 1 wherein the plane of said webs is substantially parallel to the plane of said textile positioned below said webs.
 5. The mechanism of claim 1 wherein a comb-like device having teeth is positioned between said web and said textile in the discharge path of said dye.
 6. The device of claim 5 wherein means is provided to adjust the angle of said teeth with respect to the plane of said textile therebelow.
 7. The device of claim 5 wherein the teeth of said comb are rounded in an upward turn.
 8. The device of claim 1 wherein said band member is supported and driven by a pair of rotating rollers positioned on opposite sides of said textile.
 9. The device of claim 1 wherein said band Member comprises two loop members positioned on opposite sides of a plane through said dye streams and said web members are supported at each end thereof by one of said loop members. 